How We Built a 12MW Solar Plant on Hard Soil in Pakistan

Table of Contents

• Project Overview: A Landmark 12MW Installation
• Geological Challenges: The Hard Soil Conundrum
• Precision in Construction: Engineering Solutions On-Site
• Local Empowerment: Building Capacity and Ensuring Quality
• Grace Solar: The Force Behind the Project
• Continued Commitment: The Future in Pakistan and Beyond

Project Overview: A Landmark 12MW Installation

On the vast lands of Pakistan, a significant stride was made in renewable energy adoption with the successful grid connection of a 12MW ground-mounted photovoltaic power plant. This landmark project, executed in two distinct phases (8MW + 4MW), stands as a testament to tailored engineering and resilience. The entire installation was supported by custom-designed ground-mounted racking systems from Grace Solar, a leader in smart solar mounting solutions. The successful completion under challenging conditions highlights the critical role of adaptable and robust infrastructure in global solar deployments.

Figure 1: Completed 12MW solar plant showcasing the scale of installation

Figure 2: GS-Smart ground mounting system installation detail

This project represents one of many large-scale installations in Grace Solar's global portfolio, which now exceeds 48GW of cumulative installed capacity across more than 100 countries. The phased approach allowed for iterative problem-solving and optimization, ultimately delivering a reliable power generation asset that will contribute to Pakistan's energy security for decades.

Geological Challenges: The Hard Soil Conundrum

The initial phase of construction presented an immediate and formidable obstacle: exceptionally hard soil that rendered conventional ground screw installation nearly impossible. Upon receiving feedback from the field, Grace Solar's dedicated R&D team swiftly conducted an analysis, confirming the site was comprised of dense cobblestone strata. This prompt diagnosis was crucial. The team quickly adapted the installation methodology, engineering a custom solution that could penetrate the tough terrain.

This agile problem-solving at the very foundation stage laid the groundwork for all subsequent progress, preventing major delays. The experience gained from this challenge has since been integrated into Grace Solar's global engineering protocols, enhancing our capacity to address similar geological conditions in future projects across Asia, Africa, and the Middle East.

Precision in Construction: Engineering Solutions On-Site

Even with an optimized plan for the second 4MW phase, new precision challenges emerged. During installation, some screws exhibited rotational deviation, threatening the structural integrity and timeline. Demonstrating their "Do it right the first time" core value, Grace Solar's technical team initiated an emergency protocol. Utilizing advanced 3D simulation, they reconstructed the installation process virtually and identified angular misalignment as the root cause.

Figure 3: Technical team conducting precision measurements on-site

Figure 4: Aerial view showing precision alignment of completed arrays

Technicians were immediately dispatched to the site to perform real-time adjustments and corrections. This hands-on, technical expertise resolved the issue efficiently, ensuring the entire 12MW plant was connected to the grid as scheduled, a remarkable feat under the dual pressures of time and natural constraints. The incident highlighted the importance of having both advanced simulation capabilities and experienced field technicians working in tandem—a combination that defines Grace Solar's approach to complex projects worldwide.

Local Empowerment: Building Capacity and Ensuring Quality

Following the physical completion, Grace Solar's commitment extended beyond hardware. The team conducted comprehensive stability tests on the installation system under simulated environmental conditions, where the racking performed exceptionally. True to the philosophy of "Global Technology, Local Adaptation," the project included a vital knowledge-transfer component.

Grace Solar conducted systematic technical training for the local construction team, covering specialized techniques for difficult geology and rigorous installation quality control. This blend of theoretical and hands-on guidance empowered the local workforce and built invaluable in-country expertise for the future operation and maintenance of the plant, as well as for upcoming projects in the region.

This investment in local capacity building ensures the long-term sustainability of the project and strengthens Pakistan's renewable energy sector as a whole. It reflects Grace Solar's commitment to being more than just an equipment supplier—we are partners in developing sustainable energy infrastructure worldwide.

Grace Solar: The Force Behind the Project

This project's success is a direct reflection of the strength and scale of Grace Solar. As part of the BYMEA Group with a registered capital of 500 million, Grace Solar brings substantial resources to every challenge. With a global cumulative installed capacity of 48GW and ranking among the top 5 in global market share, our experience is vast.

Our team of over 650 professionals, including highly sophisticated engineers, operates from a 110,000 m² factory and a dedicated 2,000 m² experiment center. We hold over 100 patents and global certifications (UL, TUV, CE, JIS, etc.), ensuring every product, like the GS-Smart ground mounting system used in Pakistan, is engineered to be "firm as rock." Our mission to "Mount every solar plant firm as rock, bring more profits from the sun" was proven on the ground in Pakistan.

Continued Commitment: The Future in Pakistan and Beyond

The Pakistan project is a blueprint for future endeavors. Grace Solar is committed to deepening localization services in Pakistan and surrounding regions. By integrating continuous technological innovation with hard-earned engineering experience from projects in over 100 countries, we are poised to provide reliable, customized support for more photovoltaic projects in complex environments.

We invite partners and clients facing unique installation challenges to contact us for tailored solar mounting solutions. Together, we will drive the clean energy transition in South Asia and contribute professional expertise to the green energy cooperation under the "Belt and Road" initiative, moving steadily toward our vision to "Bring Grace Solar to all homes."